U.S. patent number 11,296,472 [Application Number 16/157,197] was granted by the patent office on 2022-04-05 for hand crimp tool having wire inserter.
This patent grant is currently assigned to TE Connectivity Services GmbH. The grantee listed for this patent is TE CONNECTIVITY CORPORATION. Invention is credited to Chadwick Alan Kerstetter, Caleb Andrew Moyer.
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United States Patent |
11,296,472 |
Kerstetter , et al. |
April 5, 2022 |
Hand crimp tool having wire inserter
Abstract
A hand crimp tool includes a handle having upper and lower
handles having upper and lower handgrips hand squeezed to close the
hand crimp tool. The hand crimp tool includes a head having upper
and lower jaws defining a crimp zone therebetween. The lower jaw
includes an anvil holding a terminal and the upper jaw includes a
crimper crimping the terminal. The hand crimp tool includes a wire
inserter coupled to the head having a carriage movable between an
advanced position and a retracted position. The wire inserter has a
wire clamp holding a wire in the carriage and the wire inserter
moves the wire relative to the head to position and hold the wire
in the terminal during crimping of the terminal between the anvil
and the crimper.
Inventors: |
Kerstetter; Chadwick Alan
(Richfield, PA), Moyer; Caleb Andrew (Harrisburg, PA) |
Applicant: |
Name |
City |
State |
Country |
Type |
TE CONNECTIVITY CORPORATION |
Berwyn |
PA |
US |
|
|
Assignee: |
TE Connectivity Services GmbH
(N/A)
|
Family
ID: |
1000006217573 |
Appl.
No.: |
16/157,197 |
Filed: |
October 11, 2018 |
Prior Publication Data
|
|
|
|
Document
Identifier |
Publication Date |
|
US 20200119506 A1 |
Apr 16, 2020 |
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01R
43/0421 (20130101); H01R 43/045 (20130101); Y10T
29/53226 (20150115); H01R 43/042 (20130101) |
Current International
Class: |
H01R
43/045 (20060101); H01R 43/042 (20060101) |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Other References
International Search Report, International Application No.
PCT/IB2019/058605, International Filing Date, Oct. 9, 2019. cited
by applicant.
|
Primary Examiner: Tugbang; A. Dexter
Claims
What is claimed is:
1. A hand crimp tool comprising: a handle including an upper handle
and a lower handle movable relative to each other to open and close
the hand crimp tool, the upper handle including an upper handgrip,
the lower handle including a lower handgrip, the upper handgrip and
the lower handgrip configured to be hand squeezed to close the hand
crimp tool; a head having an upper jaw operably coupled to the
upper handle and a lower jaw operably coupled to the lower handle,
the head including a crimp zone between the upper jaw and the lower
jaw, the lower jaw including an anvil configured to hold a
terminal, the upper jaw including a crimper configured to crimp the
terminal between the anvil and the crimper when the hand crimp tool
is closed; and a wire inserter coupled to the head, the wire
inserter including a carriage movable between an advanced position
and a retracted position, the wire inserter having a wire clamp
holding a wire in the carriage, the wire inserter moving the wire
relative to the head to position and hold the wire in the terminal
during crimping of the terminal between the anvil and the crimper,
wherein the wire inserter includes a carriage lock operably coupled
to the carriage, the carriage lock locking the carriage in the
retracted position, the carriage lock being released to move the
carriage to the advanced position.
2. The hand crimp tool of claim 1, wherein the wire inserter
includes a biasing mechanism coupled to the carriage, the biasing
mechanism biasing the carriage toward the advanced position to load
the wire into the terminal.
3. The hand crimp tool of claim 2, wherein the biasing mechanism
applies a biasing force on the carriage to spring load the wire in
the terminal at a predetermined loading force during crimping of
the terminal.
4. The hand crimp tool of claim 3, wherein the wire inserter
includes a force adjustment mechanism operable to adjust the
loading force.
5. The hand crimp tool of claim 2, wherein the wire inserter
includes an end piece coupled to the head by guide rails, the
carriage positioned between the end piece and the head on the guide
rails and sliding on the guide rails between the retracted position
and the advanced position, the biasing mechanism being positioned
between the end piece and the carriage.
6. The hand crimp tool of claim 5, wherein the guide rails control
a direction of movement of the carriage in an advancing direction
during positioning of the wire by the wire inserter, and wherein
the biasing mechanism controls a depth of movement of the carriage
in the advancing direction during positioning of the wire by the
wire inserter.
7. The hand crimp tool of claim 1, further comprising a terminal
locator coupled to the head proximate to the anvil, the terminal
locator having a terminal channel configured to receive the
terminal oriented relative to the anvil, the terminal locator
having a terminal lock configured to lock the terminal in the
terminal channel.
8. The hand crimp tool of claim 7, wherein the terminal locator
includes a locating feature configured to engage the terminal to
locate the terminal in the terminal channel relative to the
anvil.
9. The hand crimp tool of claim 1, wherein the wire clamp includes
a clamping finger configured to engage the wire and hold the wire
in the carriage, the wire clamp having a clamp lever operable to
move the wire clamp between a clamped position and a released
position.
10. A hand crimp tool comprising: a handle including an upper
handle and a lower handle movable relative to each other to open
and close the hand crimp tool, the upper handle including an upper
handgrip, the lower handle including a lower handgrip, the upper
handgrip and the lower handgrip configured to be hand squeezed to
close the hand crimp tool; a head having an upper jaw operably
coupled to the upper handle and a lower jaw operably coupled to the
lower handle, the head including a crimp zone between the upper jaw
and the lower jaw, the lower jaw including an anvil configured to
hold a terminal, the upper jaw including a crimper configured to
crimp the terminal between the anvil and the crimper when the hand
crimp tool is closed; and a wire inserter coupled to the head, the
wire inserter including a carriage movable between an advanced
position and a retracted position, the wire inserter having a wire
clamp holding a wire in the carriage, the wire inserter moving the
wire relative to the head to position and hold the wire in the
terminal during crimping of the terminal between the anvil and the
crimper, the wire inserter including a biasing mechanism coupled to
the carriage, the wire inserter including an end piece coupled to
the head by guide rails, the carriage positioned between the end
piece and the head on the guide rails and sliding on the guide
rails between the retracted position and the advanced position, the
biasing mechanism being positioned between the end piece and the
carriage, the biasing mechanism biasing the carriage toward the
advanced position to load the wire into the terminal.
11. The hand crimp tool of claim 10, wherein the biasing mechanism
applies a biasing force on the carriage to spring load the wire in
the terminal at a predetermined loading force during crimping of
the terminal, the wire inserter including a force adjustment
mechanism operable to adjust the loading force.
12. The hand crimp tool of claim 10, wherein the guide rails
control a direction of movement of the carriage in an advancing
direction during positioning of the wire by the wire inserter, and
wherein the biasing mechanism controls a depth of movement of the
carriage in the advancing direction during positioning of the wire
by the wire inserter.
13. The hand crimp tool of claim 10, wherein the wire inserter
includes a carriage lock operably coupled to the carriage, the
carriage lock locking the carriage in the retracted position, the
carriage lock being released to move the carriage to the advanced
position.
14. The hand crimp tool of claim 10, further comprising a terminal
locator coupled to the head proximate to the anvil, the terminal
locator having a terminal channel configured to receive the
terminal oriented relative to the anvil, the terminal locator
having a terminal lock configured to lock the terminal in the
terminal channel, the terminal locator including a locating feature
configured to engage the terminal to locate the terminal in the
terminal channel relative to the anvil.
15. The hand crimp tool of claim 10, wherein the wire clamp
includes a clamping finger configured to engage the wire and hold
the wire in the carriage, the wire clamp having a clamp lever
operable to move the wire clamp between a clamped position and a
released position.
16. A hand crimp tool comprising: a handle including an upper
handle and a lower handle movable relative to each other to open
and close the hand crimp tool, the upper handle including an upper
handgrip, the lower handle including a lower handgrip, the upper
handgrip and the lower handgrip configured to be hand squeezed to
close the hand crimp tool; a head having an upper jaw operably
coupled to the upper handle and a lower jaw operably coupled to the
lower handle, the head including a crimp zone between the upper jaw
and the lower jaw, the lower jaw including an anvil configured to
hold a terminal, the upper jaw including a crimper configured to
crimp the terminal between the anvil and the crimper when the hand
crimp tool is closed; a terminal locator coupled to the head
proximate to the anvil, the terminal locator having a terminal
channel configured to receive the terminal oriented relative to the
anvil, the terminal locator having a terminal lock configured to
lock the terminal in the terminal channel, the terminal locator
including a locating feature configured to engage the terminal to
locate the terminal in the terminal channel relative to the anvil;
and a wire inserter coupled to the head, the wire inserter
including a carriage movable between an advanced position and a
retracted position, the wire inserter having a wire clamp holding a
wire in the carriage, the wire inserter moving the wire relative to
the head to position and hold the wire in the terminal during
crimping of the terminal between the anvil and the crimper.
17. The hand crimp tool of claim 16, wherein the wire inserter
includes a carriage lock operably coupled to the carriage, the
carriage lock locking the carriage in the retracted position, the
carriage lock being released to move the carriage to the advanced
position.
18. The hand crimp tool of claim 16, wherein the wire inserter
includes a biasing mechanism coupled to the carriage, the biasing
mechanism biasing the carriage toward the advanced position to load
the wire into the terminal, the biasing mechanism applies a biasing
force on the carriage to spring load the wire in the terminal at a
predetermined loading force during crimping of the terminal, the
wire inserter including a force adjustment mechanism operable to
adjust the loading force.
19. The hand crimp tool of claim 16, wherein the wire inserter
includes a biasing mechanism coupled to the carriage, the biasing
mechanism biasing the carriage toward the advanced position to load
the wire into the terminal, the wire inserter including an end
piece coupled to the head by guide rails, the carriage positioned
between the end piece and the head on the guide rails and sliding
on the guide rails between the retracted position and the advanced
position, the biasing mechanism being positioned between the end
piece and the carriage.
20. The hand crimp tool of claim 19, wherein the guide rails
control a direction of movement of the carriage in an advancing
direction during positioning of the wire by the wire inserter, and
wherein the biasing mechanism controls a depth of movement of the
carriage in the advancing direction during positioning of the wire
by the wire inserter.
Description
BACKGROUND OF THE INVENTION
The subject matter herein relates generally to hand crimp
tools.
Crimping machines are used to crimp terminals to wires. Various
crimping machines are electrically actuated using a motor to drive
the crimper to crimp the terminal to the wire. Such machines use a
device to automatically position the wire in the crimp zone by
controlling the position of the end of the wire in the crimp zone.
Other various crimping machines are hand tools used to crimp the
terminal to the wire. Such hand tools are hand crimped by squeezing
the tool by hand. The wire is typically held in one hand of the
operator and the tool is squeezed by the operator's other hand.
However, the wire may be inconsistently positioned, leading to
variations in the manufactured assemblies. Additionally, if the
wire is inserted with too little force, the terminal may be
improperly crimped to the wire and may be inoperable leading to
waste.
A need remains for a hand crimp tool that repeatably and reliably
positions the wire in the crimp zone during the crimping
operation.
BRIEF DESCRIPTION OF THE INVENTION
In one embodiment, a hand crimp tool is provided including a handle
including an upper handle and a lower handle movable relative to
each other to open and close the hand crimp tool. The upper handle
includes an upper handgrip and the lower handle includes a lower
handgrip. The upper handgrip and the lower handgrip are configured
to be hand squeezed to close the hand crimp tool. The hand crimp
tool includes a head having an upper jaw operably coupled to the
upper handle and a lower jaw operably coupled to the lower handle.
The head includes a crimp zone between the upper jaw and the lower
jaw. The lower jaw includes an anvil configured to hold a terminal
and the upper jaw includes a crimper configured to crimp the
terminal between the anvil and the crimper when the hand crimp tool
is closed. The hand crimp tool includes a wire inserter coupled to
the head. The wire inserter includes a carriage movable between an
advanced position and a retracted position. The wire inserter has a
wire clamp holding a wire in the carriage and the wire inserter
moves the wire relative to the head to position and hold the wire
in the terminal during crimping of the terminal between the anvil
and the crimper.
In another embodiment, a hand crimp tool is provided including a
handle including an upper handle and a lower handle movable
relative to each other to open and close the hand crimp tool. The
upper handle includes an upper handgrip and the lower handle
includes a lower handgrip. The upper handgrip and the lower
handgrip are configured to be hand squeezed to close the hand crimp
tool. The hand crimp tool includes a head having an upper jaw
operably coupled to the upper handle and a lower jaw operably
coupled to the lower handle. The head includes a crimp zone between
the upper jaw and the lower jaw. The lower jaw includes an anvil
configured to hold a terminal and the upper jaw includes a crimper
configured to crimp the terminal between the anvil and the crimper
when the hand crimp tool is closed. The hand crimp tool includes a
wire inserter coupled to the head. The wire inserter includes an
end piece and guide rails extending from the end piece to the head.
The guide rails are coupled to the head. The wire inserter includes
a carriage slidable along the guide rails between an advanced
position and a retracted position. The carriage is closer to the
head in the advanced position than in the retracted position but
the carriage is closer to the end piece in the retracted position
than in the advanced position. The carriage holds a wire and moving
the wire relative to the head to position the wire in the terminal
during crimping of the terminal between the anvil and the
crimper.
In one embodiment, a hand crimp tool is provided including a handle
including an upper handle and a lower handle movable relative to
each other to open and close the hand crimp tool. The upper handle
includes an upper handgrip and the lower handle includes a lower
handgrip. The upper handgrip and the lower handgrip are configured
to be hand squeezed to close the hand crimp tool. The hand crimp
tool includes a head having an upper jaw operably coupled to the
upper handle and a lower jaw operably coupled to the lower handle.
The head includes a crimp zone between the upper jaw and the lower
jaw. The lower jaw includes an anvil configured to hold a terminal
and the upper jaw includes a crimper configured to crimp the
terminal between the anvil and the crimper when the hand crimp tool
is closed. The hand crimp tool includes a terminal locator coupled
to the head proximate to the anvil. The terminal locator has a
terminal channel configured to receive the terminal oriented
relative to the anvil. The terminal locator has a terminal lock
configured to lock the terminal in the terminal channel. The hand
crimp tool includes a wire inserter coupled to the head. The wire
inserter includes a carriage movable between an advanced position
and a retracted position. The wire inserter has a wire clamp
holding a wire in the carriage and the wire inserter moves the wire
relative to the head to position and hold the wire in the terminal
during crimping of the terminal between the anvil and the
crimper.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a hand crimp tool in accordance
with an exemplary embodiment.
FIG. 2 is a perspective view of a portion of the hand crimp tool
illustrating a wire inserter in accordance with an exemplary
embodiment.
FIG. 3 is a perspective view of a portion of the hand crimp tool
showing a terminal positioned in a terminal locator in accordance
with an exemplary embodiment.
FIG. 4 is a perspective view of a portion of the hand crimp tool
showing a terminal positioned in a terminal locator in accordance
with an exemplary embodiment.
FIG. 5 is a perspective view of a portion of the hand crimp tool
showing a wire loaded in a carriage of the wire inserter in
accordance with an exemplary embodiment.
FIG. 6 is a perspective view of a portion of the hand crimp tool
showing a wire clamp of the wire inserter in the clamped position
in accordance with an exemplary embodiment.
FIG. 7 is a perspective view of a portion of the hand crimp tool
showing a carriage lock of the wire inserter in accordance with an
exemplary embodiment.
FIG. 8 is a perspective view of a portion of the hand crimp tool
showing the wire loaded into the terminal in accordance with an
exemplary embodiment.
FIG. 9 is a perspective view of a portion of the hand crimp tool
showing the terminal in accordance with an exemplary
embodiment.
FIG. 10 is a perspective view of a portion of the hand crimp tool
showing the wire clamp in a released position in accordance with an
exemplary embodiment.
FIG. 11 is a perspective view of a portion of the hand crimp tool
showing the carriage in a retracted position in accordance with an
exemplary embodiment.
FIG. 12 is a perspective view of a portion of the hand crimp tool
showing the terminal lock unlocked from the terminal in accordance
with an exemplary embodiment.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a perspective view of a hand crimp tool 100 in accordance
with an exemplary embodiment. The hand crimp tool 100 is used for
hand crimping a terminal 102 to a wire 104. For example, the hand
crimp tool 100 may be opened and closed during a crimping process
to crimp the terminal 102 to the wire 104. The hand crimp tool 100
is hand actuated by an operator to close the hand crimp tool 100
during the crimping process. In an exemplary embodiment, a contact
106 is provided at the end of the wire 104 and loaded into the
terminal 102 with the wire 104. The terminal 102 is crimped to the
wire 104 around the contact 106. For example, the contact 106
defines a center contact terminated to a center conductor of the
wire 104 and the terminal 102 defines an outer contact terminated
to a shield of the wire 104. In other various embodiments, the wire
104 is provided without the contact 106 and the terminal 102 is
terminated to the center conductor of the wire 104.
The hand crimp tool 100 includes a handle 110 and a head 112 at the
end of the handle 110. The head 112 defines a crimp zone 114 and
holds the terminal 102 in the crimp zone 114 for crimping the
terminal 102 during the crimping process. A wire inserter 200 is
provided at the head 112 for loading the wire 104 into the crimp
zone 114. The wire inserter 200 positions the wire 104 in the crimp
zone 114 and holds the wire 104 in the terminal 102 during the
crimping process. In an exemplary embodiment, the wire inserter 200
holds the wire 104 in the terminal 102 using a spring force to
position the wire 104 and/or the contact 106 in the terminal
102.
The head 112 includes an upper jaw 120 and a lower jaw 122. The
handle 110 actuates the upper jaw 120 and/or the lower jaw 122
during the crimping process to crimp the terminal 102 around the
wire 104. The crimp zone 114 is defined between the upper jaw 120
and the lower jaw 122. The lower jaw 122 includes an anvil 124 that
supports the terminal 102 in the crimp zone 114. The upper jaw 120
includes a crimper 126 that crimps the terminal 102 between the
crimper 126 and the anvil 124 during the crimping process when the
hand crimp tool 100 is closed. In various embodiments, the crimper
126 and the anvil 124 are removable and replaceable within the jaws
120, 122 for crimping different sized and shaped terminals 102.
With reference to FIG. 2, in an exemplary embodiment, the anvil 124
includes a terminal support 130 having a profile that corresponds
to the terminal 102 to support the terminal 102 from below during
the crimping process. The terminal 102 may be formed against the
terminal support 130 during the crimping process. The anvil 124
includes a base 132 below the terminal support 130. Optionally, the
base 132 is coupled to the head 112 and/or the handle 110. In
various embodiments, the anvil 124 includes a ledge 134 at the top
of the base 132. The ledge 134 may rest on the lower jaw 122 of the
head 112 and/or on the handle 110 to position the anvil 124 within
the hand crimp tool 100.
With reference to FIG. 2, in an exemplary embodiment, the crimper
126 includes a crimper slot 140 that receives the terminal 102 and
forms the terminal 102 during the crimping process. The crimper
slot 140 has a predetermined profile that is used to shape the
terminal 102 during the crimping process. For example, legs of the
terminal 102 may be folded over by the crimper 126 when received in
the crimper slot 140 during the crimping process. The crimper 126
includes a base 142 coupled to the head 112 and/or the handle 110.
In various embodiments, the crimper 126 includes a ledge 144 below
the base 142. The ledge 144 may be supported by the upper jaw 120
of the head 112 and/or the handle 110 to position the crimper 126
within the hand crimp tool 100.
The handle 110 includes an upper handle 150 and a lower handle 152
movable relative to each other to open and close the hand crimp
tool 100. The upper handle 150 includes an upper handgrip 154 and
the lower handle 152 includes a lower handgrip 156. The upper
handgrip 154 and the lower handgrip 156 are hand squeezed together
by the operator to close the hand crimp tool 100. In an exemplary
embodiment, the front end of the upper handle 150 defines part of
the head 112, such as the upper jaw 120. Optionally, the front end
of the lower handle 152 may define part of the head 112, such as
the lower jaw 120.
In various embodiments, such as in the illustrated embodiment, the
handle 110 includes a clamp 160 operably coupled between the upper
handle 150 and the lower handle 152. The clamp 160 includes a lever
162 coupled to the upper handle 150. The front end of the clamp 160
defines part of the head 112, such as the lower jaw 122. When the
lower handle 152 is squeezed closed, the lower handle 152 presses
against the clamp 160 to close the lower jaw 122 to crimp the
terminal 102 to the wire 104. For example, the lower handle 152 may
be pivotably coupled to the upper handle 150 and include a cam
surface that engages the clamp 160 to close the lower jaw 122 when
the lower handle 152 is hand squeezed closed.
The hand crimp tool 100 may be opened and closed by other means in
alternative embodiments. For example, the hand crimp tool 100 may
be provided without the clamp 160, such as with the lower handle
152 defining the lower jaw 122 that is opened and closed by opening
and closing the lower handle 152 relative to the upper handle 150.
Optionally, the hand crimp tool 100 may include a return spring 164
coupled between the upper handle 150 and the clamp 160 and/or the
lower handle 152. The return spring 164 may force the lower jaw 122
to open relative to the upper jaw 120.
In an exemplary embodiment, the hand crimp tool 100 includes a
terminal locator 170 coupled to the head 112 at the crimp zone 114.
Optionally, the terminal locator 170 is coupled to the lower jaw
122 opposite the wire inserter 200. For example, the wire inserter
200 is on a first side of the anvil 124 and the terminal locator
170 is on an opposite second side of the anvil 124. The terminal
locator 170 supports the terminal 102 relative to the anvil 124.
Optionally, the terminal locator 170 may lock the position of the
terminal 102 relative to the anvil 124 during loading of the wire
104 into the terminal 102 and during the crimping process. The
terminal locator 170 may release the terminal 102 after the
terminal 102 is crimped to the wire 104.
The wire inserter 200 is coupled to the head 112 proximate to the
crimp zone 114. In the illustrated embodiment, the wire inserter
200 is coupled to the lower jaw 122 and is movable with the lower
jaw 122. The wire inserter 200 includes a end piece 202 mounted to
the lower jaw 122 by guide rails 204. The wire inserter 200
includes a carriage 206 slidable along the guide rails 204 between
the end piece 202 and the lower jaw 122. The carriage 206 holds the
wire 104 and moves the wire 104 into the terminal 102. In an
exemplary embodiment, the carriage 206 includes a wire clamp 208
operable to hold the wire 104 relative to the carriage 206. The
wire clamp 208 may be released to release the wire 104 from the
carriage 206. In an exemplary embodiment, the carriage 206 includes
a carriage lock 210 configured to lock the position of the carriage
206 relative to the end piece 202, such as for loading the wire 104
into the carriage 206. The carriage lock 210 may be unlocked to
allow the carriage 206 to advance the wire 104 into the terminal
102.
FIG. 2 is a perspective view of a portion of the hand crimp tool
100 illustrating the wire inserter 200 relative to the anvil 124
and the crimper 126. FIG. 2 also illustrates the terminal locator
170. In an exemplary embodiment, the base 142 of the crimper 126
includes an opening 146 for receiving a pin or fastener for
securing the crimper 126 to the upper jaw 120 (shown in FIG. 1). In
an exemplary embodiment, the anvil 124 includes an opening 136 for
receiving a pin or fastener for securing the anvil 124 to the lower
jaw 122 (shown in FIG. 1). In an exemplary embodiment, the anvil
124 includes guide openings 138 that receive the guide rails 204 of
the wire inserter 200 to position the wire inserter 200 relative to
the anvil 124. The guide rails 204 guide movement of the carriage
206 relative to the anvil 124 for positioning the wire 104 relative
to the terminal 102 (both shown in FIG. 1).
The terminal locator 170 is configured to be mounted to the anvil
124 and/or the lower jaw 122 (shown in FIG. 1). The terminal
locator 170 includes a body 172 having a shoulder 174 that rests on
the anvil 124. The shoulder 174 positions the terminal locator 170
relative to the anvil 124. In the illustrated embodiment, the
shoulder 174 rest on top of the ledge 134. The shoulder 174 may
engage other portions of the anvil 124 in alternative embodiments.
The terminal locator 170 includes a slot 176 that receives a
terminal lock 178. The terminal lock 178 is slidable in the slot
176 to engage the terminal 102 and lock the terminal 102 in the
terminal locator 170. In an exemplary embodiment, the terminal
locator 170 includes a terminal channel 180 that receives the
terminal 102. The terminal lock 178 is movable into the terminal
channel 180 to engage the terminal 102 unlock the terminal 102 in
the terminal channel 180.
In an exemplary embodiment, the guide rails 204 extend between the
end piece 202 and the anvil 124. In the illustrated embodiment, the
guide rails 204 are cylindrical; however, the guide rails 204 may
have other shapes in alternative embodiments. The carriage 206
slides on the guide rails 204 between an advanced position and a
retracted position. For example, the carriage 206 is movable toward
the anvil 124 as the carriage 206 moves to the advanced position
and the carriage 206 is movable away from the anvil 124 as the
carriage 206 moves to the retracted position. The carriage 206
moves the wire 104 into the terminal 102 as the carriage 206 is
moved to the advanced position.
Optionally, the guide rails 204 may be secured to the end piece 202
using nuts 212 or other fasteners. For example, ends of the guide
rails 204 may be threaded to receive the nuts 212. The guide rails
204 fix the position of the end piece 202 relative to the anvil
124. The guide rails 204 guide movement of the carriage 206
relative to the anvil 124.
In an exemplary embodiment, the end piece 202 includes a body 214
cantilevered from and along a first side of the anvil 124 by the
guide rails 204. The end piece 202 supports a biasing mechanism 220
used for biasing the carriage 206 in an advancing direction toward
the advanced position. The biasing mechanism 220 is positioned
between the end piece 202 and the carriage 206. The biasing
mechanism 220 pushes the carriage 206 away from the end piece 202
with a predetermined loading force. In the illustrated embodiment,
the biasing mechanism 220 is a coil spring; however, other types of
biasing mechanisms 220 may be used in alternative embodiments. The
size of the coil spring may be selected having a predetermined
spring force that defines the loading force. The biasing mechanism
220 is received in an opening 222 in the carriage 206. The biasing
mechanism 220 presses against a surface of the carriage 206 within
the opening 222 to force the carriage 206 in the advancing
direction.
The carriage lock 210 is used to lock the carriage 206 in position
relative to the end piece 202, such as to hold the carriage 206 in
the retracted position for loading the wire 104 into the carriage
206 and positioning the wire 104 relative to the terminal 102. When
the carriage lock 210 is released, the biasing mechanism 220
advances the carriage 206 in the advancing direction.
In an exemplary embodiment, the wire inserter 200 includes a force
adjustment mechanism 224 operable to adjust the loading force. For
example, the force adjustment mechanism 224 is operably coupled to
the biasing mechanism 220 to adjust the relative position of the
biasing mechanism 220 and the end piece 202. Actuation of the force
adjustment mechanism 224 changes the loading force. In the
illustrated embodiment, the force adjustment mechanism 224 is a
screw threadably coupled to the end piece 202. Rotation of the
force adjustment mechanism 224 changes the position of the end of
the biasing mechanism 220 to adjust the loading force. Other types
of force adjustment mechanisms 224 may be used in alternative
embodiments.
The carriage lock 210 includes a body 230 extending between a first
end 232 and a second end 234. The first end 232 is coupled to the
carriage 206. The second end 234 is configured to engage the lower
jaw 122 of the head 112 to lock the position of the carriage 206 in
the retracted position. In an exemplary embodiment, the carriage
lock 210 may be moved to an unlocked position to release the
carriage 206. For example, the carriage lock 210 may be slid
forward to the unlocked position. In other various embodiments, the
carriage lock 210 may be rotated downward to the unlocked position.
Other movements are possible in alternative embodiments. Other
types of locking devices may be used for the carriage lock 210 in
alternative embodiments.
The carriage 206 includes a carriage body 240 extending between a
first end 242 and a second end 244. The carriage body 240 includes
a front 246 and a rear 248. The carriage body 240 includes a top
250 and a bottom 252. In the illustrated embodiment, the carriage
lock 210 is coupled to the carriage body 240 at the front 246. For
example, the carriage body 240 includes a slot 254 at the front 246
and/or the bottom 252 that receives the first end 232 of the
carriage lock 210. The carriage 206 includes a wire channel 256 at
the top 250 that receives the wire 104. Optionally, the wire
channel 256 includes wire gripping features 258 for holding the
wire 104 in the wire channel 256, such as by a friction fit. For
example, the wire gripping features 258 may be serrations, grooves,
protrusions, or other features to axially hold the wire 104 in the
wire channel 256.
In an exemplary embodiment, the wire clamp 208 is pivotably coupled
to the carriage body 240 proximate to the wire channel 256. For
example, the wire clamp 208 may be coupled to the top 250 of the
carriage body 240. The wire clamp 208 includes a clamp lever 260
operable to move the wire clamp 208 between a clamped position and
a released position. Optionally, the clamp lever 260 is spring
actuated. The clamp lever 260 may be lockable in the clamped
position and/or the released position. In an exemplary embodiment,
the wire clamp 208 includes a clamping finger 262 at a distal end
of the wire clamp 208. The clamping finger 262 is configured to
engage the wire 104 and hold the wire 104 in the carriage 206. The
clamping finger 262 is movable when the clamp lever 260 is actuated
between the clamped position and the released position.
FIGS. 3 through 12 illustrate the hand crimp tool 100 in various
stages of operation. FIGS. 3 and 4 are perspective views of a
portion of the hand crimp tool 100 showing the terminal 102
positioned in the terminal locator 170. The terminal locator 170
positions the terminal 102 in the crimp zone 114 such that a crimp
barrel 190 of the terminal 102 is axially aligned with the anvil
124 and supported on the terminal support 130. FIG. 3 illustrates
the terminal lock 178 in an unlocked position. FIG. 4 illustrates
the terminal lock 178 in a locked position.
In an exemplary embodiment, the terminal locator 170 includes a
locating feature 182 extending into the terminal channel 180 to
locate the terminal 102 in the terminal channel 180. In the
illustrated embodiment, the locating feature 182 is a tab extending
into the terminal channel 180. Other types of locating features 182
may be provided in alternative embodiments. The locating feature
182 is received in a groove 192 of the terminal 102 to axially
locate the terminal 102 within the terminal channel 180.
The terminal lock 178 is slidable within the slot 176 between the
locked position and the unlocked position. In an exemplary
embodiment, the terminal lock 178 is spring loaded in the slot 176
and biased to the locked position. When the terminal lock 178 is
pushed rearward, the terminal 102 may be loaded into the terminal
channel 180 and/or removed from the terminal channel 180. When the
terminal lock 178 is released, the biasing spring forces the
terminal lock 178 to the locked position. A locking feature 184 of
the terminal lock 178 engages the terminal 102 to lock the terminal
102 in the terminal channel 180. For example, the locking feature
184 may be a tab received in the groove 192 of the terminal 102.
The terminal lock 178 may stop axial movement and/or rotational
movement of the terminal 102 within the terminal channel 180 in the
locked position.
FIG. 5 is a perspective view of a portion of the hand crimp tool
100 showing the wire 104 loaded in the carriage 206. The wire 104
is loaded in the wire channel 256, such as from above the top 250
of the carriage 206. FIG. 5 illustrates the wire clamp 208 in the
released position. In an exemplary embodiment, the end of the wire
104 is prepared prior to loading the wire 104 into the carriage
206. For example, the contact 106 may be crimped to the end of the
center conductor of the wire 104. A portion of the shield may be
exposed by removing a portion of the outer jacket of the wire 104.
The end of the wire 104 extends beyond the carriage 206 and is
axially aligned with the terminal 102. In an exemplary embodiment,
the end of the contact 106 is positioned adjacent the back end of
the terminal 102, such as approximately flush with the back end of
the terminal 102 and/or the anvil 124. When the carriage 206 is
released and advanced the end of the wire 104 may be spring loaded
into the terminal 102.
FIG. 6 is a perspective view of a portion of the hand crimp tool
100 showing the wire clamp 208 in the clamped position. The clamp
lever 260 is actuated to rotate the clamping finger 262 to the
clamped position. The clamping finger 262 engages the wire 104 and
holds the wire 104 in the wire channel 256 in the clamped position.
In an exemplary embodiment, the wire 104 is loaded in the carriage
206 when the carriage 206 is in the retracted position. In an
exemplary embodiment, the carriage lock 210 holds the carriage 206
in the retracted position. For example, the second end 234 of the
carriage lock 210 abuts against the lower jaw 122 and prevents
movement of the carriage 206 in the advancing direction.
FIG. 7 is a perspective view of a portion of the hand crimp tool
100 showing the carriage lock 210 unlocked from the head 112 to
allow the carriage 206 to advance in the advancing direction. In
the illustrated embodiment, the carriage lock 210 is slid outward
such that the second end 234 has clearance beyond the lower jaw
122. Once the carriage lock 210 clears the lower jaw 122, the
carriage 206 is allowed to advance in the advancing direction to
load the wire 104 into the terminal 102.
FIG. 8 is a perspective view of a portion of the hand crimp tool
100 showing the wire 104 loaded into the terminal 102. The carriage
206 is advanced to the advanced position by the biasing mechanism
220. The carriage 206 slides along the guide rails 204 to the
advanced position. The biasing mechanism 220 pushes the carriage
206 away from the end piece 202 to load the wire 104 into the
terminal 102. The biasing force of the biasing mechanism 220
defines the loading force of the wire 104 into the terminal 102.
The guide rails 204 control the direction of movement of the
carriage 206 in the advancing direction and the biasing mechanism
220 controls the depth of movement of the carriage 206 in the
advancing direction during positioning of the wire 104 by the wire
inserter 200. The biasing mechanism 220 maintains the loading force
on the wire 104 in the terminal 102 during the crimping process. In
an exemplary embodiment, the carriage 206 is free-floating relative
to the lower jaw 122 in the advanced position. For example,
clearance is provided between the carriage 206 and the lower jaw
122 that would allow the carriage 206 to advance further, such as
if a higher loading force is desired.
Optionally, the wire 104 may have a minimum loading force and a
maximum loading force. The biasing force of the biasing mechanism
220 is sufficient to provide a loading force that is greater than
the minimum loading force and less than the maximum loading force.
For example, the minimum loading force may be based on the force
required to insert the contact 106 beyond locating features of the
terminal 102, such as barbs within the terminal 102. In various
embodiments, the minimum loading force may be approximately 10
Newtons. The maximum loading force may be defined by the locating
features within the terminal 102 and may be selected so that the
contact 106 does not damage the locating features within the
terminal 102 during loading. In various embodiments, the maximum
loading force may be approximately 20 Newtons. In an exemplary
embodiment, the biasing force may be selected to provide a loading
force that is approximately centered between the minimum loading
force and the maximum loading force, such as approximately 15
Newtons. The loading force may be adjusted by actuating the force
adjustment mechanism 224.
FIG. 9 is a perspective view of a portion of the hand crimp tool
100 showing the terminal 102 crimped between the anvil 124 and the
crimper 126. The upper jaw 120 and/or the lower jaw 122 are closed
during the crimping process to crimp the terminal 102 to the wire
104. The upper handle 150 and/or the lower handle 152 are hand
squeezed by the operator to close the hand crimp tool 100 during
the crimping process. The wire inserter 200 holds the wire 104 in
the terminal 102 during the crimping process. The loading force on
the wire 104 is maintained through the crimping process.
FIG. 10 is a perspective view of a portion of the hand crimp tool
100 showing the crimper 126 open and showing the wire clamp 208 in
the released position. After the terminal 102 is crimped to the
wire 104, the wire 104 may be released from the wire inserter 200.
For example, the wire clamp 208 is moved to the released position
to release the clamping finger 262 from the wire 104. When the wire
clamp 208 is released, the carriage 206 may be movable relative to
the wire 104. For example, the terminal 102 is crimped to the wire
104 and held in the terminal locator 170, but the carriage 206 may
be moved to the retracted position without moving the wire 104 or
the terminal 102.
FIG. 11 is a perspective view of a portion of the hand crimp tool
100 showing the carriage 206 moved to the retracted position. In an
exemplary embodiment, the carriage 206 is moved by hand relative to
the wire 104 in a retracting direction. Once the carriage 206 is
moved to the retracted position, the carriage lock 210 may be
actuated and moved to a locked position to lock the carriage 206 in
the retracted position relative to the lower jaw 122.
FIG. 12 is a perspective view of a portion of the hand crimp tool
100 showing the terminal lock 178 unlocked from the terminal 102.
The terminal lock 178 is unlocked to release the terminal 102 from
the terminal locator 170 and the head 112. The wire 104 and the
terminal 102 may be removed from the crimp zone 114 after the
terminal lock 178 is unlocked. In other various embodiments, the
terminal lock 178 may be unlocked and the terminal 102 and the wire
104 removed from the crimp zone 114 prior to retracting the
carriage 206 to the retracted position.
It is to be understood that the above description is intended to be
illustrative, and not restrictive. For example, the above-described
embodiments (and/or aspects thereof) may be used in combination
with each other. In addition, many modifications may be made to
adapt a particular situation or material to the teachings of the
invention without departing from its scope. Dimensions, types of
materials, orientations of the various components, and the number
and positions of the various components described herein are
intended to define parameters of certain embodiments, and are by no
means limiting and are merely exemplary embodiments. Many other
embodiments and modifications within the spirit and scope of the
claims will be apparent to those of skill in the art upon reviewing
the above description. The scope of the invention should,
therefore, be determined with reference to the appended claims,
along with the full scope of equivalents to which such claims are
entitled. In the appended claims, the terms "including" and "in
which" are used as the plain-English equivalents of the respective
terms "comprising" and "wherein." Moreover, in the following
claims, the terms "first," "second," and "third," etc. are used
merely as labels, and are not intended to impose numerical
requirements on their objects. Further, the limitations of the
following claims are not written in means-plus-function format and
are not intended to be interpreted based on 35 U.S.C. .sctn.
112(f), unless and until such claim limitations expressly use the
phrase "means for" followed by a statement of function void of
further structure.
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